What’s New in Process Technology May 2013

Make the unpredictable totally predictable.

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0513

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY MAY 2013

CONTENTS

The Fluke VT02 Visual IR Thermometer bridges the gap between low-cost IR thermometers and higher priced thermal imagers and allows you to see beyond temperature at a price that’s equally

4

Improving the bottom line

groundbreaking.

Reducing the cost of compressed air

Now, instead of the tedious tasks of taking

10

Hot products online

12

New products

38

As I see it

Waste opportunities - transforming waste energy into cost-saving and sustainable processes

and recording multiple, individual temperature readings, you get the complete picture with a blended visual and thermal image of your target area.

Using hyper-thin pyroelectric technology, Fluke discovered a way to push the limits of this technology pioneering an array dense enough to create an infrared heat map. In the past, blending has been the exclusive territory of thermal imagers but not anymore. It’s standard with your new visual thermometer.

Measure with confidence, detect issues instantaneously, pinpoint with hot and cold markers, document problems with SmartView software and troubleshoot efficiently.

With the Fluke VT02 Visual Thermometer, you get the visual image of exactly what you are measuring. So whether you are an electrician, electrical contractor or work in HVAC, industrial maintenance, automotive or general maintenance, the Fluke VT02 Visual Thermometer will help you measure with confidence, diagnose problems instantly and expand your business.

Fluke Australia Pty Ltd www.fluke.com.au

NOW in DIGITAL! Your copy of What's New in Process Technology is now available as an online eMag.

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IMPROVING THE BOTTOM LINE REDUCING THE COST OF COMPRESSED AIR

© iStockphoto.com/ TimTheToolman

© iStockphoto.com/polygraphus

Clayton W Fryer, IMI Norgren, Littleton, Colorado

4 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

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© iStockphoto.com/SimplyCreativePhotography

The cost of compressed air continues to be a very elusive subject in industrial applications. The notion that compressed air is free is a common misconception.

C

ountless attempts at making end users aware of the costs to produce compressed air have largely been ignored. It seems that operations managers are concerned with the power consumption of a couple of 60 W light bulbs, but couldn’t care less about the power required to run a 400 hp compressor. Let’s put this into perspective - one horsepower equals 745.7 W. You can light 4971 light bulbs with the same power it takes to run a 300 kW compressor. Indeed, the single largest electrical appliance in a manufacturing plant may be the compressor motor.

Compressed air costs are typically hidden in the operating overheads of most companies, therefore any overhead cost reduction immediately falls to the bottom line in the form of profit. The real test of this improved bottom line is determining the additional sales a company must generate to produce a similar profit.

Real costs Experts in the compressed air field suggest the cost to produce compressed air varies from $0.15 to $0.40 per 1000 standard cubic feet (SCF)1,2, depending on geographical location. In spite of these estimates, a large sector of the user public fails to complete the simple calculations to determine what a machine will require in terms of standard cubic feet per minute (SCFM) of compressed air, let alone for an entire year or the life of the equipment. In order to improve the bottom line with pneumatics, we must also expose three popular pneumatic myths: • Myth 1: Compressed air is free • Myth 2: Pipe size = Right size • Myth 3: If a little bit’s good, a whole lot’s better

Myth 1: Compressed air is free In the past most people wouldn’t take the time to determine the cost of the compressed air required by an actuator for a year. It is ironic that hydraulic system designers have to do the calculations in order to determine the size of the power unit required to operate hydraulic cylinders. For far too long, little effort has been made to recognise the

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similarities between hydraulic and pneumatic systems. Typically, fluid power people have defended the differences between hydraulic and pneumatic systems. By recognising the similarities we can design and service the two mediums from similar perspectives, including the need for safety, conservation, component sizing and cost justification.

There is a developing interest in determining the cost of compressed air in a pneumatic system. We are beginning to see users specify 60 psig as the maximum pressure range for a pneumatic system.

Pneumatic component manufacturers are somewhat paranoid about discussing the cost of compressed air for fear they might encourage customers to apply a substitute for compressed air. Since compressed air is readily available, affordable, clean and has less force hazards than hydraulic power, it seems reasonable that compressed air will continue to be applied in the industrial sector.

Real common sense To properly apply pneumatic components in a system, the first component to be considered is the actuator. We have seen a large number of cylinders grossly oversized resulting in poor actuator performance, wasted compressed air and high initial component costs. Oversizing an actuator by one bore size can result in a 50% increase in the cost of compressed air required for the application. If the cylinder is sized to move more than twice the load at the design pressure, the cylinder speed will be adversely affected and the cost of compressed air will also increase. Using this simple observation can result in significant savings.

If care is taken at this step of the design process, every component upstream of the actuator (valves, conductors, fittings, filters, regulators and lubricators) will have a better chance of being correctly sized and applied.

A good and correct start in the process is essential to having an efficient system.

Real calculations A cylinder flow calculation is required for a number of reasons. It takes into consideration the force required to move the load at the

MAY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Fluid power

OVERSIZING AN ACTUATOR BY ONE BORE SIZE CAN RESULT IN A 50% INCREASE IN THE COST OF COMPRESSED AIR REQUIRED FOR THE APPLICATION.

Figure 1: Typical valve/cylinder/flow control circuit.

specified pressure, the extend and retract stroke volumes of the cylinder, the cycles per minute, the operating air pressure and a conversion to SCFM. SCFM is the value used by most pneumatic fluid power manufacturers to apply the correct components in a system. SCFM is also linked to valve sizing using the flow coefficient (Cv).

Once the cylinder flow calculation is completed, the designer can determine the correct tubing, fittings, valves and the filter, regulator and lubricator (FRL) for the application. In spite of the obvious benefits this information provides, we find few designers attempting these critical calculations.

In a typical circuit (Figure 1) comprising a double-acting pneumatic cylinder, a five-port, four-way valve and two flow controls, the typical approach to sizing exposes another popular pneumatic myth.

Myth 2: Pipe size = Right size If the cylinder selected had a 1/2″ pipe port, most installers would apply 1/2″ flow controls, 1/2″ pipe and fittings, a 1/2″ valve and, quite possibly, a 1/2″ FRL! This approach leads to oversized, high-priced components and higher long-term operating compressed air costs over the life of the equipment.

As a result, oversizing components occurs frequently and quickly leads to another popular pneumatic myth.

Real-life example Let’s consider the following example. We have a cylinder load that requires 2.2 kN of force to move in the extend direction only.

The retract stroke has no effective load.

We want to move the load 30 cm and be able to do this at 30 cycles per minute, eight hours per day, five days per week, 50 weeks per year. The cylinder will be operated on a horizontal plane. Compressed air pressure is 80 psig (552 kPa). Of course, we want this cylinder to move as fast as possible (AFAP)!

Real solution There are five steps required to accurately calculate a cylinder flow rate (in SCFM).

The calculations are necessary to achieve accurate results. After the calculations are completed the system designer has the information needed to make sound, costeffective decisions that include downsizing components and conserving compressed air.

Step 1: Size the cylinder for maximum performance This is the stage in sizing a cylinder where we find many designers throwing in a little extra safety factor to cover breakaway forces of a cylinder (if a little bit’s good, a whole lot’s better!)

Based on common practice and the orientation of the cylinder, we have found the range of the force multiplier to be between 1.25 to 2 times the load3 being moved, at the specified pressure. This range of values will provide adequate force compensation in the calculations and need not be exceeded.

To size the cylinder for maximum performance (quickest stroke time) we will apply the x2 rule. Multiply the load by two and apply the correct cylinder at the specified pressure. In this case, 2.2 kN x 2 = 4.4 kN. Using the formula, force is equal to pressure

6 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

times area (f=pA), we solve for the crosssectional area we need for the cylinder bore.

To solve for the area, the formula looks like A=f/p. 4.4/552= 0.008 m2 = 80 cm2 is the cross-sectional area of the bore needed to move our 2.2 kN load as fast as possible!

This is very close to a standard ISO bore of 100 mm (78.5 cm2). It is IMPORTANT to note here that any larger bore size will move slower at 80 psig and any smaller bore size will also move slower. Use a 100 mm bore cylinder.

Step 2: Calculate total volume per cycle Total volume per cycle requires some examination of the cylinder we will be applying.

We need to recognise that the extend stroke volume will be more than the retract stroke volume on a typical double-acting, single-rod cylinder, due to the volume displacement of the rod.

Since we’ve selected an ISO 100 mm bore cylinder we will apply the standard 25 mm rod (after we’ve checked to avoid cylinder rod buckling!). Extend volume is equal to the bore cross-sectional area times the stroke length.

78.5cm2 x 30cm = 2355cm3

Retract volume (compensating for the rod) calculation is:

(78.5cm2 – 4.9cm2) x 30cm = 2208cm3

Total volume per cycle is therefore:

2355cm3 + 2208cm3 = 4563cm3

For a 125 mm bore the total volume per cycle is:

3681cm3 + 3440cm3 = 7121cm3

That’s a 56% increase over the volume of the 100 mm bore cylinder!

Step 3: Calculate total volume per minute Multiply the total volume per cycle by the number of cycles per minute: 4563cm3/cycle x 30cpm = 136,890cm3/min

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© iStockphoto.com/polygraphus

© iStockphoto.com/ TimTheToolman

Fluid power

Step 4: Convert to cubic feet/minute (CFM)

136,890cm3 ÷ 16.387cm3/in3 ÷ 1728in3/ft3 = 4.83CFM

Step 5: Convert CFM to SCFM This conversion reduces the cylinder flow calculation to the necessary and required terms.

To make this conversion we must recognise the compression ratio of the compressed air being used in the application. Compression ratio is the working pressure expressed in absolute terms and converts compressed air to standard conditions (14.7 psia, 36% RH and 20ºC temperature). In most industrial applications, the ambient temperature and relative humidity can be ignored since these variables have little impact on the calculations. Our compression ratio (CR) calculation is: (80 + 14.7) ÷ 14.7 = 6.44 Multiplying the CFM by the CR = SCFM:

4.83 CFM x 6.44 CR = 31.1 SCFM

An SCFM of 31.1 for this application seems fairly harmless until you complete the compressed air cost evaluation. The cylinder flow calculation provides the necessary information (SCFM) to more accurately determine the flow coefficient (Cv) and the proper FRL for the system. Without the cylinder flow calculation, sizing the rest of the components in the system will be accomplished empirically (trial and error approach) or by using Myth 2.

With the cylinder flow calculation complete, we can move on to the real cost of compressed air for the application and sizing the rest of the components in the system.

Real power requirements Most compressor representatives will use a few rules of thumb to determine the compressor capacity required for an application.

Depending on the type of compressor used,

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compressors are typically rated to deliver four to five SCFM per horsepower as a rule of thumb. Most compressor representatives will also strongly recommend a duty cycle of 50% to 75% (rule of thumb), again depending on the type of compressor. Duty cycle is the percentage of time the compressor motor is generally running under loaded conditions.

In our application, at 50% duty cycle and at 4 SCFM/hp, a 31.1 SCFM application will require an additional compressor capacity of 11.6 kW!

(31.1 SCFM ÷ 4 SCFM/hp) ÷ 50% duty cycle = 15.55 hp (11.6 kW).

Real compressed air costs If we carry our SCFM calculations out to the number of SCF per year, per shift, pretty soon we are talking about some serious compressed air usage! Consider how many minutes there are in an eighthour day, five days a week, fifty weeks in a year: 120,000 min/year per eight-hour shift (That’s 360,000 min/year for three shifts!)

31.1 SCFM x 120,000 min = 3,732,000 SCF/yr.

The 125 mm bore cylinder would require 48.5 SCFM or 5,820,000 SCF/yr. If your average cost per 1000 SCF is only $0.25, the cost of compressed air to operate this one 100 mm bore cylinder for one shift, for the year is an incredible $933, and obviously, if your cost of compressed air is $0.50/1000 SCF, your annual cost would be $1866.00.

For the 125 mm bore, air consumption costs jump to $1455 (at $0.25/1000 SCF) and $2910 (at $0.50/1000 SCF). Over a 55% increase for one bore size increase.

Real concern The cost of compressed air actually used is a major concern for most manufacturing companies. If we could reduce the compressed air consumption in our system by 30%, most CEOs, CFOs and plant engineers would leap at the opportunity. Let’s con-

sider another approach to our application.

Since our 2.2 kN load is only being moved in the extend direction, we could consider lowering the air pressure to return the cylinder. For example, say we were able to lower the return pressure from 80 to 20 psig. How would that impact on the total system air consumption?

If you recall from Step 2 above, the retract stroke volume was 2208 cm 3 per cycle, or about 48.4% of the total cycle volume. Without taking you through the additional calculations, the compressed air cost for the extend stroke at $0.25/1000SCF is $481.43/year.

Again, without going through the calculations, it can be shown that by changing the pressure on the return stroke to 20 psig the compressed air consumption is reduced by 30%, therefore saving 30% in compressed air costs overall for this actuator.

Even if the price of a 1/2″ regulator was $50, you would be able to expect a payback on the cost of the regulator in about two months.

Please keep in mind this example is for only one 100 mm cylinder. How many cylinders are you applying? What is your cost of compressed air?

When we examine the application even closer, we are able to save even more in initial costs by properly sizing the valve, the fittings and tubing by the use of the flow coefficient (C v). It is sufficient to say the use of C vs to size a system is reasonably accurate and provides an element of cushion in most system calculations.

There are other approaches to conserving compressed air in typical applications.

If cylinder speed is not important, using a force multiplier between 1.25 and 2 times the load will result in smaller cylinders and less air consumption. Applying singleacting cylinders could significantly reduce the long-term cost of compressed air.

MAY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

Fluid power

IF

YO U

REDUCE

YO U R

COMPRESSED AIR OVERHEAD COSTS, AVOID OVERSIZING COMPONENTS AND DESIGN YOUR SYSTEMS TO OPERATE AT AN OPTIMUM PRESSURE, YOU CAN IMPROVE © iStockphoto.com/SimplyCreativePhotography

SYSTEM PERFORMANCE AND IMPROVE THE BOTTOM LINE.

Real system Cv

Using Cvs we can evaluate the typical circuit of Figure 1 for potential bottlenecks. Each component in the circuit has a Cv. With some effort it is possible to determine the C v of the cylinder port, Cv of the flow control (in both the free flow direction as well as the WIDE OPEN controlled flow direction), Cv of the piping/tubing and fittings and the Cv of the directional control valve. The System Cv is ALWAYS going to be less than the component with the smallest Cv in the system.

A strong recommendation here is to make the most restrictive component (‘the weakest link’)4 in the system the most expensive component (usually the directional control valve). This will minimise the initial cost of the components in the system. It is fair to say that a 1/2″ directional valve will cost more than a 1/4″ valve. The difference in pipe or tubing cost is marginally different.

Real savings With dual pressure savings, you can see the fast payback on applying additional regulators. More impressive savings can be realised by finding the leaks in the compressed air system and eliminating them. We have seen reports suggesting compressed air losses due to system leaks and artificial demand range from 20 to 45%!5 Compressed air leaks, left unattended, will continue to grow in size and flow due to the abrasive effect of the air-line contamination and particulate matter continuing to attack the leak orifice. 6 The sooner leaks are discovered and repaired, the less waste there is in power required to produce the compressed air. Less wasted air reduces operating costs and can justify the expense of a maintenance patrol to quickly repair air leaks.

Real maintenance After all of this discussion to reduce the operating costs associated with wasting compressed air, we must mention another, less obvious, source of waste. Users should regularly check for excess pressure drop across air filters. By applying pressure drop indicators (also called service life indicators or delta P indicators) and changing filter elements with greater frequency, you will avoid the escalating cost of the pressure drop across the filter element. Electronic and mechanical pressure drop indicators are commercially available to provide reminders to service the filter elements on a regular basis. Using pressure switches to monitor regulated pressure in the system will avoid surpassing the x2 multiplier, ensure efficient use of compressed air and provide optimum performance of the system.

In hydraulic systems, a pressure drop across a filter has serious consequences affecting the entire hydraulic power unit adversely. Poor maintenance on hydraulic filters results in catastrophic failures. In hydraulic systems, leaks are quickly repaired due to the obvious hazards and cost associated with hydraulic oil. Rarely does poor maintenance on a pneumatic filter result in catastrophic failure. However, excessive pressure drop across a pneumatic filter is an ongoing operating cost that is hidden from view. In pneumatic systems, leaks are often ignored until they become so annoying (uncomfortably loud), or they have caused such a significant system pressure drop, that they must be repaired.

Summary If you don’t care about the cost of compressed air in your plant, don’t do the calculations, and you will perpetuate the three pneumatic myths! Consider the similarities between

8 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

pneumatic and hydraulic systems, rather than the differences.

If increased profits are of interest to you, then you’ll find a hidden profit centre in the cost-effective use of compressed air. If you reduce your compressed air overhead costs, avoid oversizing components and design your systems to operate at an optimum pressure, you can improve system performance and improve the bottom line. The first step to recognising the potential savings available to you is completing these simple calculations.

With a little time and effort, you can make a big improvement on your bottom line with pneumatics.

Norgren Pty Ltd Contact info and more items like this at wf.net.au/T629

References 1. Electric Power Research Institute 1994, Compressed Air Handbook, Electric Power Research Institute, p12.

2. Wagner, HH 1999, ‘Your Total Compressor Cost May Be Too High’, Plant Engineering, May 1999.

3. Fleischer, H 1999, ‘Stop Oversizing Pneumatic Components’, Machine Design, June 1999, pp 101-106.

4. Fleischer, H 1995, Manual of Pneumatic Systems Optimization, 1st edn, McGrawHill, New York, 1995, pp 25-66.

5. Foss, RS 1998, ‘Improving Air System Efficiency Part 1’, Hydraulics & Pneumatics, April 1998, pp 41-68.

6. Foss, RS 1999, ‘Improving Air System Efficiency Part 7’, Hydraulics & Pneumatics, July 1999, pp 33-79.

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Served up on a plate

AirLINE Quick: High quality, cost effective, fast delivery Meet AirLINE Quick. AirLINE Quick has internalised all pneumatic air channels, and integrated primary and secondary components to deliver one single complete pneumatic (or electro-pneumatic) valve bank on a stainless steel adapter plate. Unlimited modularity in valves, functions, feedbacks, I/O, and accessories, is offered, with local assembly from Bürkert’s ISO 9001 Sydney Systemhaus. The stainless steel plate mounts directly into a cabinet, effectively minimising labour for cost effectiveness and fast delivery.

Same day turn-around (on lower-quantity orders) is common.

Last year Bürkert shipped around 600 panels, and this year with AirLINE Quick it could easily be thousands. Call us, and get your valve banks served up on a plate, or mounted in a cabinet, ready to go.

Ideal for end-users, OEMs, and switchboard consultants. Designed for arduous environments, for physical and chemical resistance.

www.burkert.com.au | 1300 888 868 www.burkert.co.nz | 0800 BURKERT (0800 287 537)

We make ideas flow

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH DATA RECORDER The Hioki 8860 8-channel memory recorder allows the user to conduct signal observations and recordings including voltage, current and pulse monitoring.

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> SAFETY INTERFACE MODULES The PDP20 allows series connection of various sensors up to Category 4 of AS4024, four sensors per module.

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The Axiocontrol AXC 1050 controller has an operating temperature range of -40 to +60째C. Phoenix Contact Pty Ltd

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POWER CONDITIONER BACKPLANE

The Diagnostic Power Conditioner (DPC) Backplane for FOUNDATION Fieldbus H1 provides up to four segments with redundant power and communicates diagnostics via ethernet.

Turck Australia Pty Ltd

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10 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

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NEW PRODUCTS

VIBRATION TRANSMITTER The Model 640B01 from IMI Sensors is a 4-20 mA output vibration transmitter for permanent installation.

THERMAL IMAGING CAMERA The VarioCAMhr from Infratec is a high-resolution camera for high thermal imaging

It has a measurement range of 0 to

performance. It has a modular device concept that permits the camera equipment

25.4 mm/s peak and a frequency

to be custom designed and enables the user to upgrade the camera for universal

range of 3-1000 Hz. The vibration transmitter will interface directly to PLCs, DCS

use in varied areas. Thermographic images are displayed with high quality in an adjustable, high-resolution colour viewfinder which simultaneously provides an overview of the current measuring conditions.

or SCADA control systems and

The camera has replaceable, fast rechargeable Li-Ion batteries and very low power

operates off standard 24 V loop

consumption which ensures a long working autonomy of the camera. It is offered

power. It installs quickly and pro-

with various detector formats and temperature-measuring ranges, which can be

vides an easy, cost-effective means

extended. It is supplied with high-quality infrared lenses, tools of the thermography

of continuous 24/7 monitoring and

software suite IRBIS 3 and a wide range of accessories.

protection of critical machinery, helping to reduce downtime.

While 4-20 mA sensors cannot

SciTech Pty Ltd Contact info and more items like this at wf.net.au/T359

perform diagnostic tasks, they provide early warnings that help maintenance technicians avoid catastrophic failure. Raw vibration or temperature output signal

ROD ACTUATORS

options and intrinsically safe options are also available.

The compact, heavy-duty To-

Some typical applications include critical pumps and mo-

lomatic IMA integrated linear

tors, cooling towers and fans, slow speed rolls, and rotary

servo actuator is now available

and screw compressors.

with additional ball screw offer-

Thermo Fisher Scientific

ings that more than double the

Contact info and more items like this at wf.net.au/T600

speed range, from 610 mm/s to 1473 mm/s, and is CE/UL approved.

Designed for long life in high-duty

VIBRATION SWITCH

cycles, the IMA delivers high force in

The Series VBS vibration switch is compact and uses two easy set-up dials that adjust the maximum RMS velocity set point and false trip time delay. The Series VBS is intended to continuously monitor the changes in a machine’s vibration level.

The switch takes real-time RMS vibration input and provides a 4-20 mA analog output of velocity as well as a switching output for when an alarm value is exceeded. It features easy set-up and operation, and no software is required.

Applications of the vibration switch include motors, pumps, fans, engines, compressors, centrifuges, generators, turbochargers, gearboxes and conveyors.

Dwyer Instruments (Aust) Pty Ltd Contact info and more items like this at wf.net.au/T399

press fitting systems; accurate positioning and quick response in valve and process control; compact, lightweight spot welding; and smooth velocity fluid dispensing.

When supplied with the optional food-grade white epoxy coating and stainless steel components, the IMA provides corrosion resistance, ingress protection and bacterial growth protection for food and beverage industry applications.

The IMA integrates a servo motor into a ball or roller screwdriven actuator to provide efficient high force in a compact, lightweight design. The IMA55 high-force servo linear actuator with roller screw option boosts its thrust capability to 30,470 N. The long-life design eliminates the need for couplers, adapters, belts and gears and allows for easy relubrication without disassembly.

Available in four sizes, the IMA line of integrated-motor rod actuators features stroke lengths from 76 to 457 mm.

Pneumatic Products Contact info and more items like this at wf.net.au/T326

12 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

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NEW PRODUCTS

SERVO DRIVE The MicroFlex e150 servo drive is designed to control a wide range of motion applications from simple point-to-point motion to advanced motion. The servo drive combines ethernet technology, advanced multitasking programming and single-phase operation in a compact package.

ETHERNET STRAIN RELIEF

The MicroFlex e150 can operate from

Designed for use with ethernet cables, the IE-CFK-05

105 to 250 VAC single- or three-phase

DIN rail-mount cable strain relief provides support

and is available in multiple current and

and relief for these cables once they are attached

power ratings. The drive is designed

to industrial switches. This support reduces cable

to control a wide range of demanding

fatigue and helps improve the longevity of the con-

motion applications, such as cutting

nection point at the switch.

and forming, pick and place, packag-

The device is manufactured from glass fibre reinforced plastic. Strong and durable, it can withstand harmonic oscillations in vibrating applications. This

ing, pharmaceutical/life sciences and laser/ water-jet/textile cutting machines.

The embedded ethernet interface offers EtherCAT

makes it particularly suitable for use with moving

for real-time control of multiaxis systems and with addi-

machinery and equipment that experiences high

tional software EtherNet/IP, Modbus TCP and Raw Ethernet,

levels of vibration.

enabling control possibilities with other controllers such as PLC

The device is suitable for use with the IES10 and

and industrial PCs.

IES20 series, and each unit holds up to ten cables

ABB’s MicroFlex e150 is a highly intelligent drive offering Mint programming as

simultaneously (two in each locating groove). It mounts

standard. Mint is a multitasking language that is tailored for motion applications. This

directly to the DIN rail and curves to overlap the front

simple but powerful programming language within Mint WorkBench PC tools provides

face of ethernet switches. Weidmuller standard end

control of communications, logic, motion and HMI interactions. It allows a fast and

brackets are included with each unit.

simple set-up and can be packaged into a single data file suitable for email should

At 130 mm high, the unit is compact and lightweight making integration to secure the cables simple.

Weidmuller Pty Ltd Contact info and more items like this at wf.net.au/T682

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support assistance be required.

The drive meets the latest European machinery standards for safety with the Safe Torque Off (STO) feature included as standard in accordance to IEC 61800-5-2, SIL3 PLe. ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/T727

MAY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

Cutting-edge train unloader automation boosts Fortescue’s export capabilities From humble beginnings in 2003, Fortescue has grown into the world’s fourth-largest iron ore producer. Its first mining operations started at the Cloudbreak mine in August 2007 with the construction of all mine, rail and port infrastructure reaching completion in 2008.

A critical part of the port infrastructure was the company’s train unloader, which was put into operation in April 2008 when Fortescue unloaded its first train at the Herb Elliott Port, near Port Hedland in North Western Australia. In 2010, Fortescue approved an ambitious expansion to triple production to 155 mtpa. The US$9 billion project not only includes an expansion of mining operations but an expansion of the company’s port, train unloading capacity and rail network.

For Fortescue Port Shutdowns Supervisor Brad Stillman, the company’s original train unloader, TU601 supplied by Metso, is truly at home in the harsh conditions of the Pilbara due to its sturdy construction and reliability.

“We’re not in a pharmaceutical lab - it’s a really rugged environment out here. But even so, the unloader is like a Swiss watch - everything just works. That’s why it’s my favourite piece of the plant. It is a big, heavy, powerful piece of gear that needs to be treated with respect,” he said.

On the back of the reliable performance of its first Metso train unloader commissioned in 2008, Fortescue awarded Metso Mining and Construction a contract to supply two more identical systems.

The first of the two new unloaders (TU602) was commissioned ahead of schedule in mid-September and the second (TU603) in November 2012.

Fortescue’s General Manager - Port, Gerhard Veldsman, says it was crucial that TU602 was delivered on or ahead of schedule and that the ramp-up had to go well, because the business was experiencing a “real bottleneck” when it came to unloading trains.

“It was delivered two weeks early, which was fantastic. The original ramp-up schedule was meant to be eight weeks, but we shortened that to six and we did it in four,” he said.

The early delivery of the second train unloader resulted in Fortescue being able to dump 580,000 tonnes of unbudgeted ore in September, said Veldsman.

“At $100 a tonne, that’s $58 million in extra revenue that we hadn’t counted on. So the early delivery helped cover our capital investment!” he said.

Mark Shirley, Operational Readiness and Commissioning Manager at Fortescue, adds, “Train unloader two is hugely important to the business, taking us to between 110 and 115 million tonnes capacity.

TU603 is also one of the critical parts in our supply chain; if you’ve only got two train unloaders and you lose one, you’ve lost 50% of your capability,” said Shirley.

Fortescue’s railway is the heaviest haul line in the world, with a 40-tonne axle load capacity. The company’s rail infrastructure operates 24 hours a day, seven days a week. Each train is around 2.7 km long and carries up to 32,800 tonnes of iron ore in 240 freight cars.

Trains arriving from the mine sites are moved through one of the unloaders. During unloading, two wagons are simultaneously unloaded every 90 seconds. The unloader clamps and then inverts the wagons, rotating them through 150°. This is done without uncoupling the wagons as each pair of wagons has a swivel coupling at either end. Prior to each operation, the wheels of the train are locked in place to prevent the train moving during the rotation cycle.

The contents of the wagons are dumped into a chute that feeds an apron feeder which transports the ore onto a conveyor feeding one of the facility’s stackers.

14 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

Each unloader consists of three main parts: the indexer, the tippler and the train holding devices.

The indexer is a rail-mounted vehicle that is dedicated to advancing the train through the unloader, two wagons at a time. This heavy-duty workhorse moves back and forth along a short track located at the entry to the unloader. It is moved by 13 vertically mounted drive units that turn pinions via gearboxes to pull it a long a rack mounted in the middle of the track. A retractable hydraulic arm is inserted between the wagons to push the train along by two wagons at a time.

The tippler is a rotary machine that is made up of two unloading cells.

Each cell comprises the main cell structure, a drive unit and support roller assemblies, as well as a braking and lubrication system. The tipplers are located in an enclosure which is part of a pressurisation and dust extraction system.

Each cell is equipped with train rail sections and onboard hydraulic clamps that hold the wagon in place as the cell rotates during the unloading cycle.

Coordinating the three parts of the train unloader with their myriad sensors, motors and hydraulics has been accomplished through the use of a GE Fanuc RX3i PLC. The motor starters, VVVF equipment and associated I/O are located in the switch room.

The field I/O located around the plant is connected back to the PLC via Profibus fibre optic. A GE Fanuc Cimplicity SCADA terminal in the unloader’s control room displays plant status.

While the automation of each train unloader is rather complex and is managed by a stand-alone system, each train unloader also has to coordinate with the control of the other port equipment such as apron feeders, conveyors and stackers.

More details of this project can be read in a longer version of this story, online at http://www.processonline.com.au/case_studies/60237.

Metso Minerals Contact info and more items like this at wf.net.au/T644

www.ProcessOnline.com.au

NEW PRODUCTS

MAGNETIC INCREMENTAL ENCODER The ASM POSIROT magnetic position

VALVE TERMINAL PLUG-IN

sensor range has been expanded with the combination PMIS4/PMIR5, developed specifically for rotary applications.

The advantages of this combination

Many users in the fields of

are high EMC protection, large guiding

small parts assembly and the

distance tolerance and a superior signal

electronics industry, as well as the food and

performance up to 327,680 pulses/360°.

packaging industries, in which a high flow rate for a

The incremental, non-contact measuring

small unit volume are important, can benefit from the

system consists of the sensor head PMIS4

modularity of the VG series of valve manifold systems.

and an incremental magnetic ring PMIR5. The sen-

The VTUG valve terminal plug-in for the VG range from

sor head is made of a fully enclosed, shielded metal housing. It offers

Festo offers multiple variations and a highly simple and

high protection against electromagnetic interference, thermal overload,

inexpensive fieldbus connection for all standard field-

and operating temperature range of -40 to +85°C and has a protection

buses and ethernet as well as IO-Link. The fieldbuses

class of IP67. The PMIR5 magnetic ring comes in three sizes with flange

are quick and easy to replace as the fieldbus nodes

sizes of 83, 133 or 233 mm. They are available with decadic, binary or

are screwed onto the valve terminal. This is particularly

degree division and reach correspondingly 131,072 pulses/360°, 196,608

suitable for machine and system manufacturers who

pulses/360° or 327,680 pulses/360°. Since the system operates magneti-

offer their machines and systems in modular design,

cally, it is unaffected by contamination from oil and dust. For this reason

so providing them with electrical modularity and high

it is suitable for use in harsh, dusty industrial environments.

pneumatic flexibility.

Automated Control Pty Ltd

Festo Pty Ltd

Contact info and more items like this at wf.net.au/T317

Contact info and more items like this at wf.net.au/T594

WLAN ETHERNET ADAPTER Phoenix

Contact

now offers an industrial WLAN ethernet adapter for integrating ethernet-capable devices into WLAN IEEE 802.11a/n networks (5 GHz frequency band).

The adapter has an IP67 enclosure rating and complements the WLAN ethernet adapters (WLAN clients) for the IEEE 802.11 b/g WLAN standard (2.4 GHz frequency band).

An integrated antenna has been developed to provide a high level of robustness for wireless communication in reflective industrial environments. New functions such as DCP, LLDP and Profinet prioritisation increase performance when used in automation networks. Application areas for the WLAN ethernet adapters include locations in which moving or mobile ethernet-capable devices such as controllers, terminals or I/O modules are to be integrated wirelessly into the main ethernet network.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/S921

16 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

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NEW PRODUCTS

MOTOR SHAFT GROUNDING RING The Aegis SGR conductive microfibre shaft grounding ring is designed for predictive and preventive maintenance programs on VFDcontrolled AC motors and large DC motors.

By protecting bearings from electrical damage, the SGR extends motor life, preventing bearing noise, downtime, and costly motor repairs and replacements. The Aegis SGR prevents bearing damage by channelling shaft currents to ground.

Conductive microfibres inside the SGR provide the path of least resistance, allowing these shaft currents to discharge safely to the motor frame.

Preventing shaft current damage (in many cases for the life of the motor), the Aegis SGR simplifies predictive and preventive maintenance programs for motor repair shops, maintenance contractors, HVAC service contractors and in-house maintenance departments. Unlike conventional shaft grounding brushes, the SGR’s conductive microfibres work with virtually no friction or wear; are unaffected by dirt, grease, or other contaminants; and last for the life of the motor, regardless of speed.

A mounting kit simplifies installation of the SGR on any NEMA or IEC motor and provides clearance for motors with shaft shoulders, slingers, bearing caps or end-bell protrusions.

Secured with three mounting screws and standoff posts, the entire assembly covers less than 12 mm of the motor shaft.

Morgan AM&T www.morganamt.com.au

TEMPERATURE INDICATORS The Noshok 820/821 Series digital temperature indicators are a suitable replacement for bimetal, liquid-bulb and glass thermometers in applications including pharmaceutical, food preparation, utilities and municipal, refineries, chemical and petrochemical plants, paper mills and hydraulics.

The series uses a PT100 RTD Class A element for temperature sensing and has a M12 (5-pin) plug or 36″ integral cable electrical connection. They feature

CONVEYOR SYSTEM The FlexLink X65 conveyor platform has been designed to reduce TCO and is claimed to offer twice the strength compared to the standards of today, which has an effect on the service life and maintenance intervals of systems installed. In addition, the layouts can be made simpler as fewer drives and transfers are required for a given layout due to the increased maximum conveyor length.

The X65 conveyor is designed for low friction, low power consumption and a long service life. With the addition of more efficient drive technology, power consumption is 8-44% less compared to previous high-efficiency drive units by FlexLink, depending on the configuration. X65 is also capable of double the speed compared to previous conveyor generations, at up to 120 m/min. There has also been significant noise reduction and improvements in operator safety. In most common applications, the noise level of X65 is on a typical office level, and compared to the industry standards, it is up to 80% less.

For automated single piece flow applications, the X65 pallet conveyor system offers standardised functions for the handling of products up to 3 kg. The pallets and functions are prepared for the integration of process control systems, such as track-and-trace and MES functionality.

FlexLink Systems Contact info and more items like this at wf.net.au/T496

18 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

a large 4-digit LED display and a 4-20 mA programmable linearised output signal. They are also field reprogrammable with an optional PC interface module and software, which includes a security feature to prevent accidental reprogramming.

A self-calibration feature helps ensure accurate and stable performance, and an optional fully programmable switch output (relay or transistor) is available.

The temperature indicators come in various mounting configurations, are IP65/NEMA 4 rated and have a 316 stainless steel construction.

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/T236

www.ProcessOnline.com.au

A clear view on water production for Wellington In 2008, the New Zealand Ministry of Health issued revised drinking water standards for drinking water safety. To comply, water treatment facilities must track, save and provide monthly reports on water production, intake and discharge levels. At the same time, water providers need timely usage reports to make sure municipal customers can properly budget and forecast for city water needs.

As one of the largest water producers in New Zealand, the Greater Wellington Regional Council (GWRC) understands these requirements well. The GWRC is responsible for supplying clean water to more than 10% of New Zealand’s population. Drawing water from lakes, rivers, wells and aquifers, the council is the wholesale water treatment provider for the cities of Lower Hutt, Porirua, Upper Hutt and Wellington.

In order to comply with the changing regulations, the GWRC required a reporting solution which can provide accurate and timely reports generated f ro m d a t a a u t o m a t i c a l l y retrieved from its existing water treatment production and control system infrastructure.

As a result, the GWRC was n o t o n l y a b l e t o co m p l y with government reporting requirements, but it was also able to leverage real-time production data to improve water treatment distribution, and better inform internal and external stakeholders on water production and usage.

The GWRC employs the most advanced water treatment system in New Zealand with a supervisory control and data acquisition (SCADA) system that runs four entirely automated water treatment plants, 15 pumping stations and more than 180 kilometres of pipeline.

However, collecting process data from disparate data sources proved challenging, especially since data needed to be stored in a reliable time series archive for analysis and reports. Lily Wang, data analyst for GWRC, explained that it was time consuming to manually extract and organise data from different sources within the water treatment system for required governmental compliance reports. A faster, more accurate and automated reporting system was needed; one that could generate predetermined reports automatically and share them with authorised groups. This system also needed data validation capability as well as the ability to retain 10 years of data.

“After comparing several options, Rockwell Automation provided the most advanced and impressive capabilities, meeting or even exceeding all our data collection and reporting requirements,” commented Wang.

GWRC implemented FactoryTalk Historian Site Edition (SE) and FactoryTalk VantagePoint Enterprise Manufacturing Intelligence (EMI) software onto GWRC servers. The historian provided ready connectivity to GWRC plants’ automation system controllers, with the capability to automatically pull tags directly from different controllers via interface nodes. Tags are then stored in the FactoryTalk Historian server for the required 10-year retention period. Once stored, this information is available to be retrieved

20 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

for trending comparisons and other analysing and reporting purposes.

Using FactoryTalk VantagePoint EMI software, the GWRC’s data management system is able to schedule and produce 11 automatically generated reports to provide information on weekly and daily water consumption, discharge, intake, water quality and reservoir levels, as well as reports on lake storage volumes and total flow volume.

Analysts like Wang, water production/maintenance engineers and operators, business managers, marketers and GWRC committee members charged with water supply management and regional strategy have access to this data from any location. Secure login via a web browser brings each stakeholder to a single portal where they can access predetermined dashboards and charts.

Facility operators have visibility of real-time consumption data for validation that usage levels are as expected. If demand peaks, more water can be supplied from other plants. Business managers are able to make comparisons on yearto-date usage versus the previous year to ensure billing forecasts based on past usages are accurate or to update expected revenues.

“The FactoryTalk software suite’s high level of integration and compatible connectivity to existing hardware and software components in our plants and business system has given us the ability to pull reliable data from a wide variety of sources,” Wang said.

Data is now more quickly available and accurate. “Reports that used to take me the better part of a week to create and several more days to validate can now be produced in a few minutes or even seconds,” claims Wang.

As a data analyst, Wang checks water intake and production data every day. “With real-time data immediately available, it’s as easy as doing a balance check.” In the summer of 2012, during one daily validation, more water was taken in than what was fed into the drinking-water system, signifying a leak. Wang was able to immediately contact the maintenance engineers responsible for the appropriate plant and direct them to the relevant pipeline to find and fix the leak.

The problem was discovered and solved before the leak was noticeable to production engineers or developed into a larger issue. Wang added, “Our data system is so reliable now that we’ve made it public.”

The GWRC now offers a live map of the current rate of water supply, which is updated every 15 minutes. As residents are now able to see water use by city over a monthly, quarterly and annual basis, the GWRC hopes a public that is more informed about water production and usage will better conserve water, especially in times of peak demand.

The GWRC has rolled out this same scalable solution to track system-wide chemical and power usage. “We have a firm grasp on our chemical and power inputs,” explains Wang. “We can optimise the control system to get the best information to our business managers so they get the best value from our budget.”

Rockwell Automation Australia Contact info and more items like this at wf.net.au/T561

www.ProcessOnline.com.au

NEW PRODUCTS

VIBRATION SENSOR The ifm efector VNB001 is the first member of a new series of vibration sensors. The compact sensor monitors the overall vibration condition of machines and plants according to ISO 10816 and features an onboard timestamped history function as well as data logging and trending.

The sensing principle is based on the efector octavis technology, which can also be used reliably in mobile applications. The sensor measures the effective vibration velocity in mm/s or in/s. Measured value and switching status are indicated on the LED display. Critical machine conditions can be signalled using two switching outputs or one switching output and one analog input.

As an alternative, the sensor can be powered via USB interface and used as a handheld device. The product also offers rapid, easy handling and set-up as the parameters can be adjusted directly on the device. No additional configuration software is required. ifm efector pty ltd Contact info and more items like this at wf.net.au/T271

EMBEDDED COMPUTING FOR AUTOMATION The Neousys Nuvo-1300af is a fanless embedded controller with integrated gigabit PoE ports. Incorporating high-end Intel Core i7 processor, the controller offers high performance for arithmeticintensive applications, while its -25 to 70°C fanless design provides reliability and durability.

The device integrates four gigabit PoE ports, compliant with the IEEE 802.3af standard. Each PoE port can deliver 15.4 W of power to a PoE device, such as a PoE camera. The controller also features isolated PoE power, which allows users to alternatively supply the unit from two independent power supplies, one for the PoE functionality and the other for the computer. This minimises the risk of an external power surge on an ethernet cable that may damage the system.

In addition, the device integrates versatile I/O interfaces in its compact chassis. It has one additional GbE port for data communication and two internal SATA ports for accommodating two 2.5″ SATA hard drives. The device also features onboard isolated DIO and serial ports for device control/communication.

Madison Technologies Contact info and more items like this at wf.net.au/S979

IS 8 SERIES PORTABLE DIGITAL PYROMETERS FOR ROUGH INDUSTRIAL APPLICATIONS BETWEEN 250-2500°C

DIGITAL INDICATOR The West 8010+ digital process indicator provides

■ Focusable precision optics with small measurement spots for operation at a safe working distance.

a high-contrast, high-visi-

■ View finder and 2x external temp displays.

ease of use in a wide

■ Multifunctional numeric or graphical display.

process applications.

■ Integral data logger with variable storage interval date stamping of readings with USB interface.

less configuration, plug-in output

■ Robust die-cast aluminium housing.

able, a designated transmitter power supply or up to four alarm relays

Carry case, software, USB cable, traceable calibration certificate included, together with 2 year warranty, surprisingly affordable pricing and quick delivery

bility display. The indicator is designed for optimal variety of temperature and The device provides a jumperboards and an efficient PC configurator for quick and simple set-up.

In addition, plug-in modules allow retransmission of the process vari(latching or non-latching).

The instrument provides a user-selectable dual-colour display option with fixed red or green displays or a green to red colour change when an alarm condition occurs.

Up to five outputs are supported and plug-in output modules are available for SSR driver, triac, relay and linear outputs. Self-recognition of option boards promotes simple, error-free set-up. The 10V SSR driver output allows for driving of up to three typical SSR/SCR inputs.

Modbus and ASCII communications are supported, and multipoint scaling and tare features are included as standard.

Automated Control Pty Ltd Contact info and more items like this at wf.net.au/T499

22 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

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Process Control

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RB2A01000S41 Guided Radar (TDR) Coaxial Rod 4-20mA Output HART PNP NO/NC Output, S304 Probe Thread Connection : G3/4 $1,750

LS0001 PBT M18 Thread, -20*C ~ 80*C, NO/NC Output

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NEW PRODUCTS

WEB 2.0-ENABLED RTU CSE-Semaphore has introduced a compact remote terminal unit (RTU) that integrates cybersecurity protection and wireless communications with SCADA functionality. The TBox LT2 RTU is an all-in-one unit featuring a web server, 3G wireless communications, and a complete cyber-security application suite, all integrated with programmable automation, alarm notification, data logging, and ethernet communications in a single, rugged module.

The decentralised architecture on which the TBox RTU line is built provides up to 50% cost savings over other systems that seek to combine PLC, communications and SCADA components.

The self-contained system provides everything needed to create automation and monitoring of installations and enables easy creation of push and multi-platform communications strategies. Users have complete access to alarms, live conditions and historical data on their mobile devices, tablets and PCs. TBox LT2 RTU communications include ethernet, RS232, RS485 and USB ports, and an integral 3G wireless option. Mixed I/O configurations include eight analog inputs, 16 digital I/Os selectable per point and, optionally, two analog outputs. For installations requiring additional I/O, the device readily expands using compact modules interfaced via ethernet or RS485. The highly scalable, futureproof processing platform is based on an ARM9 CPU running at 400 MHz. The memory configuration includes 32 MB Flash, 64 MB SDRAM, 1 MB SRAM and a Micro SD card with up to 32 GB capacity. TBox systems are easy to configure and offer dramatically reduced costs versus traditional PLC and SCADA architectures.

CSE-Semaphore Pty Ltd Contact info and more items like this at wf.net.au/T240

Economical & Scalable...

Pilz has a wide variety of cost effective & flexible safety solutions for your packaging machinery.

Looking for a reliable Partner for the automation of your packaging line?

ANTIVIBRATION SERVER CABINET The V-Rack series of antivibration rackmount

We offer you a comprehensive portfolio of solutions ranging from the

server cabinets is avail-

small with only a handful of sensors using our new PDP technology all

able in three different mod-

the way though to the most complex of systems utilising our PSS4000

els: V-Rack-660, V-Rack-960 and

safe automation platform.

V-Rack-1560.

Talk to us today about your packaging safety requirements!

80 kg, and measures 700 (W) x 500 (H) x 600 (D) mm, while the V-Rack-960

The V-Rack-660 features a form factor of 6U, a load capacity of up to has a form factor of 9U, and measures 653 mm high. The third model, V-Rack-1560, has a form factor of 15U, and measures 920 mm high.

The V-Rack series features a rugged shockmount design, and is constructed from high-quality aluminium and steel. It creates a space for hardware to be safe from virtually all disruptions, including constant vibration or incidental impact. With optional front and rear lockable doors, safety@pilz.com.au

www.pilz.com.au

03 9544 6300

the internal hardware is safe from theft or tampering.

ICP Electronics Australia Pty Ltd Contact info and more items like this at wf.net.au/T363

24 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

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NEW PRODUCTS

ORBITAL WELDING CALIBRATION UNIT The Swagelok M200 portable calibration unit delivers on-site power supply maintenance, providing added convenience, reduced costs and improved efficiencies that can cut servicing time lines from days to minutes.

The calibration unit allows for immediate calibration of a Swagelok welding system M200 power supply. Many quality systems require orbital welding power supplies to be calibrated periodically. Traditional calibration processes are completed off site at a designated service location, leaving operations idling or needing to incur extra expense with rental equipment. Portable calibration helps minimise downtime, which is key for remote or secured environments, such as offshore oil drilling platforms, power plants and government sites that cannot easily arrange power supply transport to and from service centres.

The portable calibration unit is designed with enhanced technology focused on promoting efficiency through the welding process.

On-screen navigation on the power supply prompts users to initiate the calibration process. The calibration unit then performs various diagnostics and measures output levels. The calibration unit is designed to specifically calibrate based on critical welding variables, including current (automatic calibration to ensure proper current output for future welds), voltage (provision of simple, on-screen adjustments to match actual values with expected values) and travel speed (electrode travel speed is verified and adjusted real time via the operating software, eliminating the need for frequent calibration).

The verification is displayed and documented as part of the calibration software, making documentation easier for users.

Swagelok Corporation Contact info and more items like this at wf.net.au/T591

INFRARED TEMPERATURE SENSOR Temperatures up to 1350째C can be measured with the new infrared temperature sensor from ifm efector. It also offers an integrated display and operating unit. Easy push-button programming ensures quick use. Additionally, the sensor features scratch-resistant precision lenses for minimum sensitivity to scattered light.

Infrared temperature measurement is used where temperatures can only be measured without contact. The sensors detect emitted infrared radiation and outputs a temperature signal. If the detected temperature is above the set switching threshold, the switching output is set and the switching status of the LED is displayed.

The switching thresholds and output configurations can be set and easily reproduced by means of the button and the display. Clearly visible LEDs always indicate the switching status. During operation the display shows the current measured value percentage. ifm efector pty ltd Contact info and more items like this at wf.net.au/T273

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MAY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

NEW PRODUCTS

ISOLATION AMPLIFIERS The Phoenix Contact Mini Analog isolation amplifier series has been expanded with new modules.

The sensors, two new temperature transducers for resistance thermometers and thermocouples, meet all relevant international standards. A DIP switch allows users to quickly set the two transducers and the modules can be easily configured for extended functions and monitoring via the robust S-Port interface using a free software tool.

A new frequency transducer transforms speed pulses from below 1 Hz up to 80 kHz into an analog signal. The module supports NAMUR sensors as well as NPN and PNP outputs. The transducer is quickly configured via a DIP switch and with the intuitive ‘TeachIn Wheel’ for freely setting measuring ranges.

In addition, a new fault monitoring module provides transparent error logging for multichannel applications with up to 80 modules that are connected via the rail-mounted connector. If an error is detected internally or in the signal input of a transducer, it is reported via the rail-mounted connector. The fault monitoring module then displays the error via an NC contact, eliminating the need for a complicated individual evaluation. If the system is further equipped with the new feed terminal, it can detect and report power supply failures.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/T178

REMOTE TERMINAL UNITS Sixnet RTUs (remote terminal units) are configured by using Sixnet’s windows-based toolkit and offer the programming flexibility of either C or ISaGRAF Open programming software which encompasses the following IEC61131-3 languages: Sequential Function Chart, Ladder Diagram, Structured Text, Instruction List, Function Block Diagram and Flow Chart.

With a Linux operating platform and open protocols such as Modbus, DNP3 and SNMP, the RTU provides the user with the flexibility to interface to a wide range of devices and with an operating temperature range of -40 to 70°C ensures reliability in harsh environments. The RTUs can also be supplied from a 10 to 30 VDC supply making them suitable for use on battery-powered systems. The I/O capacity of the RTU can be expanded by adding Sixnet EtherTrak-2 or third-party I/O modules which can be interfaced to the RTU either serially or via ethernet.

The RTU can also be interfaced to a radio system or to other technologies such as the company’s industrial cellular routers making them suitable for installation on either existing or new networks Control Logic Pty Ltd Contact info and more items like this at wf.net.au/T183

COMPACT RIGHT-ANGLE GEAR UNIT With a torque range for smaller applications of up to 180 Nm, the W series Spiroplan gear unit is the smallest, most compact and least expensive servo right-angle gear unit series SEW-Eurodrive has ever manufactured.

The single-stage Spiroplan right-angle gear unit is available in models W10, W20, W30, W37 and W47. It can be used as a stand-alone gear unit for direct motor mounting or for mounting on the motor using the low backlash adapter. The series is also available in different output versions: either with a shaft and key or with a hollow shaft and a keyway. Both versions are available with a flange-mounted design. When combined with the CMP series of synchronous servomotors, the gear unit acts as a gearmotor.

High precision, dynamics and high torque are offered in this compact version.

With the servo Spiroplan right-angle gear unit, SEW-Eurodrive has created a costoptimised drive solution with consistently low rotational clearance and a continuous positive shaft-hub connection. The wide variety of drive versions provides the user with maximum flexibility and an economic option for their application.

SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/T569

26 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

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WE KNOW WE CARE WE CUSTOMISE FOR YOU‌

E LE DRIV CTRIC MO ES T CONT & SOFT S ORS ROL & TA AUTO RTERS MATIO N

TOSHIBA INTERNATIONAL CORPORATION PTY LTD NSW Toshiba International Corporation Pty Ltd 2 Morton Street, Parramatta NSW 2150 Tel: (02) 9768 6600 Fax: (02) 9890 7546

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VICTORIA Toshiba International Corporation Pty Ltd 411 Fern Tree Gully Road, Mt Waverley VIC 3149 Tel: (03) 8541 7960 Fax: (03) 8541 7970

NEWCASTLE Toshiba International Corporation Pty Ltd UNIT 1 / 18 Kinta Drive, Beresfield NSW 2322 Tel: (02) 4966 8124 Fax: (02) 4966 8147

MACKAY Toshiba International Corporation Pty Ltd 1st Floor 41 Wood St, Mackay QLD 4740 Tel: (07) 4953 4184 Fax: (07) 4951 4203

WESTERN AUSTRALIA Toshiba International Corporation Pty Ltd 10 Anderson Pl, Perth International Airport WA 6105 Tel: (08) 6272 5600 Fax: (08) 6272 5601

Reliable products from reliable people!

Oil refinery well isolated In process plants with explosive areas, intrinsically safe (Ex-i) interfaces form a bridge between the control centre and the installed field sensors and actuators. The primary task of Ex-i signal isolators is to safely limit the energy conducted into the Ex area to an amount that is below the minimum ignition threshold of the surrounding explosive atmosphere. According to the design specifications of the EN 60079-11 standard for intrinsically safe explosion protection, these signal isolators need to ensure that all the parameters affecting intrinsic safety - such as the maximum no-load voltage, maximum short circuit current and maximum power - are adhered to even during malfunctions.

As part of ongoing plant upgrades, Oil Refinery Oberrhein (MiRO) has recently introduced a new automation solution in its blending plant. One of the changes was to replace the Blend Ratio Control concept (BRC) with an Experion Blend Controller system (EBC) from Honeywell. This changeover entailed replacing the control system’s I/O level, which is located in the central switchgear room. For the functional specification of the Ex-i interface level, which was also being upgraded, the MCR planners defined the following main goals: • Lowest possible component width so that there is minimal use of control room space, with ample spare room for future system extensions.

• Less product diversity in order to minimise warehousing and documentation costs.

• Suitability for safety-oriented measuring and control circuits.

Following a period of extensive testing of Ex-i solutions, the planners decided that the MACX Ex products from Phoenix Contact were best suited to their requirements. No matter if it’s singlechannel or dual-channel HART-compliant repeater power supplies and output isolating amplifiers, NAMUR switching amplifiers, signal duplicators, solenoid drivers or temperature transducers, all MACX Analog Ex modules are just 12.5 mm wide. This means that up to 45% less space is used on the mounting rail compared to the usual module widths of 16-22.5 mm.

The MACX analog Ex interfaces have been developed for use in safety-oriented circuits that comply with EN 61508 and have been certified accordingly by external inspectors such as TÜV Rheinland.

The interfaces all qualify for SIL 2, some even for SIL 3.

The 30 decentralised blender stations located at MiRO’s Karlsruhe plant are classed as Ex zone 1 and in parts as Ex zone 0. The field instruments, which consist of various flow meters and HART-capable 4-20 mA control and separator valves, are required to provide intrinsically safe explosion protection. The blending process also entails pump control and the analysis of tank level gauges, signalling contacts and 4-20 mA signals coming from the analysis station’s two-wire transmitters. The field instruments themselves were not exchanged as part of the plant upgrade. The signals’ pointto-point connections are provided via four-core cables up to 600 metres long. These start at the honeycomb routing terminals located in the blending plant’s central distribution station. From this station, the signals are directly routed to the Ex i isolator level, where they are passed through approximately 750 analog Ex signal isolators and then processed via C200 and C300 controllers.

The Ex i isolators are arranged into device groups of 16 and mounted in open routing frames on DIN rails. The frames, which are built in-house at MiRO, have a very compact design and are easy to maintain, so the small form factor of the MACX isolators made them perfectly suited.

28 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

Highly precise signal processing is crucial for proper operation.

Rolf Bechtold, Project Engineer in Automation Technology at MiRO, confirms the MACX devices’ excellent signal quality: “The isolating amplifiers with transistor outputs, used for analysing the counter pulses, convinced me due to their clean edges. So far, we have not encountered any processing issues with the C200 counter cards from Honeywell.”

Bechtold adds, “The MACX isolators can be used flexibly and cover all our requirements with a manageable number of product types. This is an important advantage in terms of device standardisation.”

The MACX MCR-EX-SL-RPSSI-I Ex-i repeater power supply offers a supply Ex-i input for two-wire transmitters to convert signals from the analysis station and also a non-supply Ex-i input for the 4-20 mA signals from the flow meters. The device passes on the HART-transparent 0/420 mA signals to the passive and active analog C300 input cards. Says Bechtold: “This flexibility was fantastic for migration within a running system, and it also provides a number of advantages for wiring. Again, it is very useful to us that the isolating amplifiers feature two relay or transistor outputs. Thanks to the MACX devices’ Ex properties, we were able to retain all of our field instruments. This would have been much less straightforward using any other range of Ex isolators available on the market today.”

The MACX Analog Ex isolators turned out to be a perfect match for MiRO’s requirements. This is proven by how well the blender upgrade has been performing in production over the past 18 months.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/T566

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NEW PRODUCTS

DRIVES Unidrive M is designed specifically for manufacturing automation applications and each model has been tailored to a specific application. Control Techniques’ Unidrive M offers a wide variety of functionality and solutions for motor control applications with a range of 0.25 kW to 1.2 MW. Voltage ranges available are 100-120, 200-240, 380-480, 500-575 and 500-690 V. Users can select from seven levels of functionality and Intelligent Machine Architecture (IMA) allows the devices to be linked together through ethernet, enabling easy integration into machine designs. Motor control supports standard induction, permanent magnet, servo and linear motors in open or closed loop configurations.

Onboard real-time ethernet with hardware-based Precision Time Protocol (IEEE 1588 V2) provides fast and flexible communications and synchronisation. Fast installation and start-up, intuitive keypads, software tools and easy cable management minimise installation costs.

The units fit existing mountings and cable connections, with trouble-free parameter transfer for existing Control Techniques’ Unidrive SP and Commander SK users.

TESTING SOFTWARE PLATFORM VeriStand 2012 is the latest version of NI’s configuration-based software environment with an open, intuitive software interface for developing real-time testing applications. Engineers can use the 2012 version of NI VeriStand to perform high-speed data acquisition and logging and to find useful data faster during post-processing with additional data logging flexibility. They can get up and running faster using new hardware configuration utilities and NI SC Express integration makes acquiring conditioned measurements easier than ever before.

The product supports real-time model execution from a variety of modelling environments and has an open, extensible architecture to create custom code modules or incorporate custom user interfaces. It also offers built-in test automation using the Stimulus Profile Editor and integration with the NI hardware I/O library, including FPGAs, embedded networks, machine vision, RF and a range of multifunction data acquisition modules including instrument-grade I/O.

Control Techniques Australia Pty Ltd

National Instruments Australia

Contact info and more items like this at wf.net.au/T756

Contact info and more items like this at wf.net.au/T318

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MAY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

NEW PRODUCTS

SIS DIGITAL VALVE CONTROLLER The Fisher Fieldvue DVC6200 SIS digital valve controller responds to safety demands, and features partial stroke and position monitoring capabilities for the final control element in a safety instrumented system (SIS). Intelligent automatic partial stroke valve testing provides improved safety and reliability versus traditional pneumatic and jammer partial stroke methods.

The DVC6200 SIS combines the field-proven, linkage-less, noncontact feedback design of the DVC6200 and DVC2000 platforms with the safety demand and automatic partial stroke testing capability of the DVC6000 SIS. The DVC6200 SIS has been evaluated to the latest version of IEC 61508 (2010) and is certified as a SIL 3-capable device for both 4-20 mA and 0-24 VDC power settings.

An integral position transmitter is available with the DVC6200 SIS and is capable of reading valve position even on loss of power to the digital valve controller. The position monitoring safety function has been evaluated independently from the digital valve controller safety function and is SIL 2 capable.

Partial stroke valve testing can be used in service to safely increase the period of time between proof-testing the final control element. Additionally, the DVC6200 SIS confirms solenoid operation and captures useful diagnostic data during a trip event.

Emerson’s DeltaV SIS provides out-of-the-box tools that allow direct access to the DVC6200 SIS diagnostics and partial stroke data, and the ability to set up and run the partial stroke tests automatically.

Emerson Process Management Contact info and more items like this at wf.net.au/T684

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NEW PRODUCTS

REFRIGERANT COMPRESSED AIR DRYERS CompAir Australasia has announced the FX series of energyefficient refrigerant compressed air dryers. With flow capacities from 0.5 to 90.10 m3/min, the FX

TORQUE SENSORS

series can satisfy the requirements

With the compact 8661 series

for clean and dry compressed air

of torque sensors, burster is

for a wide variety of applications

extending its portfolio of products to include the acquisition

and industry sectors.

For flow capacities up to 1.6 m /min the FXS series models produce 3

of static and rotating torques

pure, clean and dry compressed air from a simple, yet robust refrigerant

over the range from 0.05 Nm up to

dryer design. High-quality compressed air is assured due to good dew-

200 Nm. In addition to its highly accu-

point performance under all conditions. These models are suitable for

rate measurements - down to 0.05% of full

point-of-use applications such as in hospitals and laboratories as they are

scale - the 8661 series offers a high level of reliability and security.

both quiet in operation and have a small footprint. A static condenser and

An optional, integrated USB interface also provides the travel-

waste heat recovery system further ensures an energy-efficient solution

ling user with easy, mobile display and documentation of the

with the lowest operating costs.

measured values.

The larger FXR series models, for flow capacities starting at

The torque sensor is suitable in fields such as precision and

2.5 m3/min, utilise an advanced stainless steel plate heat exchanger as well

micromechanics, test-bed equipment for electric motors, or in the

as advanced separation and refrigeration technology for optimum life cycle

motor vehicle industry, where torque and the associated angular

costs as well as dependable and energy-efficient operation. For absolute

position and rotation speed are important process magnitudes.

control, monitoring and diagnostics on the larger FXT series models, the

It is also suitable for laboratory research and development projects in

System Control Monitor II can be incorporated. This LED display provides

medical technology, in the chemical industry, and in quality control.

key information such as chiller inlet and discharge refrigerant temperatures,

ADM Instrument Engineering Group

allowing for an energy-efficient refrigerant compressed air dryer solution.

Contact info and more items like this at wf.net.au/T429

The FX series from CompAir are easy to install and simple to connect.

Flow capacity ranges from 0.5-90.10 m3/min. R-134a or R-407c refrigerant is used in all of the FX series models.

CompAir (Australasia) Limited Contact info and more items like this at wf.net.au/T095

EMBEDDED SYSTEM The TANK-820-H61 embedded system from IEI Technology features a second-generation Intel Core H61 low-power desktop processor, onboard 2 GB DDR3 memory and a DDR3 SO-DIMM slot, supporting up to 10 GB memory. The device also offers flexible PCI/PCIe expansion slots, and with dual PCIe GbE LAN and RS232/422/485 serial ports, it provides powerful communication performance.

The device accepts wide-range DC power input, 9-24 V, allowing it to be powered anywhere. It also has an easy-to-install, hot-swappable fan module to ensure that a PCI/PCIe expansion card with high power consumption can operate under high-temperature conditions.

Several I/O options are available, including 2x USB 3.0 ports, 4x USB 2.0 ports, a SATA 3 Gbps port, 2x GbE LAN ports, a VGA port, a DVI-I port, a line-out and a mic-in connector. The device is designed to operate efficiently in harsh environments and is able to resist strong vibration, making it suitable for installation in mobile applications.

ICP Electronics Australia Pty Ltd Contact info and more items like this at wf.net.au/T427

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MAY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

Process Technology Roadshows

2013 SERIES

PROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETY

NOW IN ITS 9TH YEAR Coming soon ... to a city near you!

If you work in mining, minerals, metals processing, utilities, food and chemical manufacturing and processing then the Process Technology Roadshows are designed for you. Don’t miss out ...

NEW TRAINING SESSIONS FOR 2013

• Engineering quiz on process instrumentation

with prizes

Substation automation • • Perform basic troubleshooting of a typical industrial ethernet system • Simulate and troubleshoot a Modbus/TCP master communicating with a Modbus/TCP slave over IEEE 802.11 (Wi-Fi)

Design and construct your own closed circuit TV • (CCTV) system for a mine site and analyse the network traffic • Troubleshoot a tuning problem with your Flow Loop • Use Tunnelling to connect a local OPC* client to a remote OPC server via the internet

Brisbane • June 17 Gladstone • June 18 Mackay • June 19 Townsville • June 20

Previous Exhibitors include:

Includes FREE: Supported by:

Training by:

• Access to exhibition • Training sessions - NEW • Lunch and networking drinks • Product demonstrations • Prize draws

To register or for more info visit: www.regionalroadshows.com.au

NEW PRODUCTS

FIELD METROLOGY WELL The Fluke 9190A Ultra-Cool Field Metrology Well is a small, lightweight and accurate dry-block calibrator. It is suitable for pharmaceutical, biomedical and food processing applications that demand strict quality control and regulatory process compliance. This includes on-location validation and calibration of RTDs, thermocouples, thermometers and other temperature sensors.

The 9190A conforms to EURAMET cg-13 guidelines for best measurement practices for temperature dry-block calibrators. This means its specifications for accuracy, stability, axial (vertical) uniformity, radial (well-to-well) uniformity, loading and hysteresis have been thoroughly and carefully defined and tested.

The 9190A has a wide temperature range (-95 to 140°C) to cover the coldest and warmest temperatures required in pharmaceutical, biomedical and food processing applications. Operating at ultracold temperatures is not typically available with a calibration bath. The 9190A uses no bath fluids, which keeps cleanrooms clean, makes it easier to transport and delivers faster heating/cooling rates. It offers best-in-class temperature stability (±0.015°C) for consistent and accurate results.

A ‘process’ option is available that features 4-20 mA connectors, a reference thermometer input and a 4-wire PRT/RTD input with an accuracy of ±0.02°C. It also has a reference sensor control to minimise the effects of the axial gradient when a reference PRT is aligned with short sensors.

Fluke Australia Pty Ltd Contact info and more items like this at wf.net.au/T176

WIRELESS NETWORK UPDATE Honeywell has announced the availability of OneWireless Network Release 210, which incorporates several features that make wireless technology easier to deploy and operate, and result in lower deployment and operational costs.

Enhanced features in Release 210 include over-the-air field device provisioning and a Gateway General Client Interface (GCI) made possible by the ISA100 standard; and native integration of OneWireless field networks into Honeywell’s Experion Process Knowledge System (PKS).

With the over-the-air provisioning feature, field devices can now be configured and commissioned without having to invest in handheld devices or needing to perform provisioning locally at the device. The result is faster and less costly deployment and improved worker safety.

The GCI feature, enabled by the ISA100 standard, allows operations to continue using legacy protocols and proprietary applications while making it easier to wirelessly expand those applications throughout the plant. The GCI also allows third-party client applications to communicate natively using proprietary or common field protocols with wireless field instruments over the ISA100 network.

Integration of ISA100 field device networks into Honeywell’s Experion PKS eliminates data mapping, non-value-added engineering and simplifies HMI display creation. It also allows field process alarms to be displayed on Experion’s Alarm Summary to provide operators with the data they need to make decisions. Tight integration with Experion also allows field operators and maintenance technicians to use Wi-Fi-enabled handhelds to securely access process data in real time from the field.

Honeywell Limited Contact info and more items like this at wf.net.au/T560

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MAY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

NEW PRODUCTS

GAS ANALYSER The Precisive 5 is a compact hazardous area-compliant package for unattended hydrocarbon process and natural gas analysis, using Precisive’s tunable filter spectroscopy (TFS) platform.

Precisive specialises in unattended, all-optical process monitoring sensors for a variety of natural gas, LNG/LPG/ BOG, combustion, emissions and biogas applications.

Quantitative analysis of alkane gases, specifically C1 to C5 (methane, ethane, propane, butanes and pentanes), and other light hydrocarbons is important in a variety of applications, including BTU measurement and quality analysis of natural

MOTOR CONTROLLER The Allen-Bradley SMC-50 smart motor controller includes a newly designed three-phase, fully

and biogas products.

The predominant measurement technique until now has been gas chromatography (GC), which has the ability to separate individual compounds with high selectivity, albeit with its slow response and high infrastructure requirements. For faster measurement requiring only a single heating value measurement, residual oxygen calorimetry is often used.

solid-state, siliconcontrolled rectifier (SCR) power structure.

It is designed to address the motor control needs of OEMs and end users seeking a more economical alternative to drives and more advanced control than across-the-line starters.

Rated at 200-690 VAC, and from 90 to 520 A, the SMC-50 controller is suitable for controlling motor speed and torque in a range of normal-duty applications, including pumps, compressors and short conveyors, as well as in heavy-duty applications, such as rock crushers, wood chippers, centrifugal fans and long conveyors.

The SMC-50 smart motor controller’s design improves voltage output to maximise efficiency of motor starts and stops.

For application scalability, it features nine standard starting modes, six stopping modes and several slow-speed functions.

The linear-acceleration starting mode offers the lowest starting current profile per start, consistent acceleration time and enhanced control over both torque and speed. Regardless of the starting mode chosen, the SMC-50 controller stores the actual motor start time and peak current value to assist in set-up and process optimisation.

The SMC -50 smart motor controller also uses the Allen-Bradley smart motor braking feature, engineered with automatic zero-speed shut-off to quickly stop a motor without the need for additional hardware or feedback devices.

The Precisive 5 gas analyser requires no carrier gases, no calibration gases and offers fast-response analytics without compromising accuracy, repeatability, linearity or stability in the presence of interferences. Faster-response multicomponent analysis provides significant cost savings and efficiency gains in power generation applications. Measurements take seconds rather than minutes with GC-based systems.

A Modbus communications interface enables remote and unattended deployment without constant operator intervention.

Novice users can become very proficient with minimal training.

The Precisive 5 is compliant with North America Division System (Class1Div2, Groups A/B/C/D, T4, Type 4X), North America Zone System (Class1, Zone2, Aex nA IIC T4, IP66, Ex nA IIC T4, IP66), European Zone System (EX II 3G n IIC

Rockwell Automation Australia

T4 Gc) and worldwide certification to IECEx standards.

Contact info and more items like this at wf.net.au/T400

Australian Dynamic Technologies Company Pty Ltd Contact info and more items like this at wf.net.au/T500

34 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

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NEW PRODUCTS

BOX PC The EPS-QM77E box PC is powered by the third generation Intel Core i5/i7 processors and is a small footprint embedded computer designed to be both fanless and ruggedised. It supports up to 8 GB of DDR3 memory, dual display with DVI-I and HDMI, 5.1-ch audio and dual Intel gigabit ethernet ports. It also provides an mSATA and two SATA interfaces, four USB 3.0 ports, two USB 2.0 ports and two serial ports.

EPS-QM77E withstands industrial operation environments for temperatures between

EXPLOSION-PROOF LEVEL METER

-10 and +60°C. It also supports a 9-19 V input range, with an anti-interference capability and protects the computer from overload. Product reliability and stability are certified by industrial product quality tests, including antivibration of up to 5 grms and antishock of up to 50 grms. While rugged, the chassis

The PD6801 ProtEX level meter from

offers easy maintenance and integration. There is an access door from the bottom side to allow easy installation

Precision Digital is an easy-to-read,

of storage drives and memory. The design and placement of the internal SBC allows for minimal cabling to

4-20 mA, loop-powered, explosion-

lower the number of connections and points of possible failures. In addition, the optional table-mount bracket

proof meter designed for safe or

allows easy mounting. The EPS-QM77E is compatible with a wide range of operating systems.

hazardous environments, such as oil wells or chemical storage. The meter has FM, ATEX, CSA and IECEx

Backplane Systems Technology Pty Ltd Contact info and more items like this at wf.net.au/T564

approvals and is housed in a rugged, cast aluminium NEMA 4X enclosure.

SafeTouch through-glass buttons allow operation without removing the cover, ensuring the integrity of the unit. Operating temperatures range from -40 to 75°C. The PD6801 features an upper display that is 1.5 cm high and shows level. The lower display is 1 cm high and shows volume, per cent or a custom tag programmable for any seven alphanumeric digits.

The backlit meter is easy to read from a distance, under various lighting conditions, and from wide viewing angles of up to ±40°.

Four sensors in the PD6801 operate as through-glass buttons for programming and operation without removing the cover in hazardous areas. These SafeTouch buttons are standard and allow high- or low-level alarm acknowledgement while being designed to prevent unintended triggers.

A 20-segment tank level indicator provides a quick view of height and will flash to alert operators about alarm conditions. It can be scaled independently of the analog input scale. For non-linear signals, such as measuring the volume of odd-shaped tanks, the PD6801 features multipoint linearisation up to 32 points. The level and volume scales can use different numbers of linearisation points.

Precision Digital Corporation http://www.predig.com

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MAY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

NEW PRODUCTS

ENCLOSURE COOLERS Vortec enclosure coolers keep electrical and electronic enclosures cool, clean and protected and are a low-cost alternative to expensive, high-maintenance air conditioners - while avoiding contamination with dirty, humid air that can be introduced by fans.

Today’s small, compact multifunction electronic controls, variable speed drives, servos and programmable logic controllers can be sensitive to heat and contamination. Smaller cabinet sizes make temperature control difficult and prone to premature failures. Excessive heat will cause digital displays to misread, controls to drift and breakers to trip below rated loads. The result is productivity lost due to machine or line shutdowns.

Vortex enclosure coolers maintain a slight pressurisation of the cabinet to keep electrical and electronic components clean and dry; and most are thermostatically controlled to maintain enclosure temperatures within a specified temperature range.

Vortec offers multiple types of enclosure coolers to meet the needs of different applications, all available in a variety of cooling capacities and ratings.

Knight Pneumatics Pty Ltd Contact info and more items like this at wf.net.au/T501

COMPRESSED AIR FILTERS High filtration efficiency is the prerequisite for high air quality while a low-pressure drop helps to save energy. To that end, Atlas Copco recently released its latest generation DD+, PD+, DDp+ and PDp+ filters.

Micro-glass fibre filter media and a six-layer wrapped construction ensure high-purity filtration and a guaranteed performance over the filter lifetime. Moreover, the performance is independent of the relative humidity. The perforated stainless steel metal cores were enhanced to ensure high mechanical strength and drastically reduce the risk of implosion.

Compared to the previous generation, the pressure drop of the new DD + and PD+ filters has been reduced and at the same time the oil aerosol carryover decreased by more than 20%.

These DDp+ and PDp+ dust filters have extremely high particle removal efficiencies of 99.92% and 99.98% respectively.

The filters are now fully certified according to ISO standards by notified bodies, both in-house as well as in external labs. This third-party certification ensures customers the air quality they require and improved energy savings.

Atlas Copco Compressors Australia Contact info and more items like this at wf.net.au/T563

36 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

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AS I SEE IT WASTE OPPORTUNITIES: TRANSFORMING WASTE ENERGY INTO COST-SAVING AND SUSTAINABLE PROCESSES

A.B.N. 22 152 305 336 Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 AUSTRALIA ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au ph: +61 3 9381 2952 Editor Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor Janette Woodhouse Publisher

A

round half of the primary energy consumed in industrial processes is currently wasted. Even steel produced by recycling scrap metal in electric-arc furnaces, for instance, requires approximately 370 kWh per metric tonne. In this type of furnace an electric arc is struck between several electrodes. The resulting heat causes the steel to melt before emitting a mixture of gases at up to 1700°C - a huge waste that might otherwise be used in the process or to generate electric power.

Predictions suggest that around 50% of costs from operating a mine, for example, will come from energy use, making it even more of an incentive for industries to reduce energy consumption as well as manage its waste more cleverly.

When considering energy efficiency, one often thinks of energy-saving technologies for lighting, heating and air conditioning, for example. But energy efficiency is so much more than this - it’s about reducing consumption while at the same time making the most of waste energy by using it in other parts of the process (for example, to preheat combustion air or serve another thermal load) or by condensing it to generate electricity.

Research has shown that up to 20% of the energy needed for melting scrap metal could be recovered from waste heat. That would reduce CO2 emissions per metric tonne of steel by about 40 kg. Current systems emit about 270 kg of CO 2, 220 kg of which results from power generation. This means that CO 2 emissions from a typical 120-tonne furnace could be reduced by more than 30,000 tonnes annually.

While it makes sense to recover waste heat, most industrial waste heat is still not captured for re-use and unfortunately, around half of the primary energy consumed in industrial processes and energy generation currently goes to waste. Part of the problem is that there are still hardly any economically practical and technically

Geoff Hird

mature processes available for waste heat below 300°C. But in a thermal management study, Siemens has identified a process called Organic Rankine Cycle (ORC) technology particularly suitable for recovering waste heat from furnaces in the glass industry, diesel or gasoline engines, gas flaring at refineries as well as gas turbines in compressor stations. The non-polluting organic medium used in this process ensures optimal efficiency for low waste-heat temperatures and low power. In a trial at Moscow State University, the ORC technology produced about 800,000 kWh of extra electricity per year with an efficiency of about 20% and a payback within three years.

In addition to producing electricity, waste heat can also be used to clean and demineralise water through an evaporation and condensation process. This not only generates new freshwater for re-use but at the same time reduces the amount of wastewater that might otherwise go to sewage.

Paper mills, soft drink bottling plants and other industries where wastewater cannot be readily disposed via a sewage treatment plant could potentially benefit from this type of technology.

Art Director/Production Manager Julie Wright Art/Production Tanya Scarselletti, Colleen Sam, Jeanette Teuma Circulation Manager Sue Lavery circulation@westwick-farrow.com.au Copy Control Mitchie Mullins Advertising Sales NSW/QLD - Nicola Fender-Fox ph: 0414 703 780 nfender-fox@westwick-farrow.com.au VIC/SA/WA - Lachlan Rainey ph: 0402 157 167 lrainey@westwick-farrow.com.au NZ - Gemma Burr ph: 0800 44 2529 gburr@westwick-farrow.com.au USA - Huson International Media East Coast ph: +1 212 268 3344 West Coast ph: +1 408 879 6666 ralph.lockwood@husonmedia.com UK - Huson International Media ph: +44 1932 56 4999 gerryb@husonmedia.com Asia - Lachlan Rainey ph: +61 (0) 402 157 167 lrainey@westwick-farrow.com.au Subscriptions For unregistered readers price on application.

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September 2012 total CAB audited circulation (Aust + NZ) 7,419 readers (83% personally requested)

Ed Sugay is Head of Energy Efficiency, Siemens Ltd. Before heading Siemens’ Energy Efficiency portfolio in Australia, Ed was Siemens’ Global D i r e c t o r o f En e rg y & Environmental S o l u t i o n s f o r As i a Pacific. Ed brings 20 years’ experience in energy generation and energy efficiency, as well as an MBA from the University of California.

38 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013

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